WAVES OF CHANGE
Creating an Eco-friendly yarn dyeing process
Water has played a vital role in carpet manufacturing for years, particularly in processes like fiber dyeing and backing. However, this heavy reliance on water has a downside - the release of harmful effluents as a significant side effect. These pollutants disrupt aquatic ecosystems, endanger wildlife, and compromise water quality, making it unsuitable for consumption, irrigation, and other essential purposes. For over 25 years, our primary objective has been to ensure that our manufacturing processes do not negatively impact the environment, operating with zero effluent output and 100% recycled water.
Water treatment at our factory
Making every drop count
Royal Thai undertook a bold mission to drastically reduce its water consumption, eliminate harmful effluents, and divert all solid waste from landfills. This initiative transcended mere business strategy, embodying a commitment to the local environment—an especially vital concern given the factory's location in a rice-growing region.
Spray Dyeing reduces water usage by 30 - 40%
The journey towards a sustainable manufacturing process was marked by cutting-edge technologies like spray drying, advanced water management, and efficient recycling systems. These innovations reduced water usage by 70% and led to a major achievement. By 2015, Royal Thai achieved 100% process water recycling and zero effluent output, underscoring their commitment to environmental stewardship and resource efficiency.
Sludge to Soil
Royal Thai surpassed standard water recycling methods by implementing a comprehensive process that includes aeration, sedimentation, and filtration to remove solid waste from the water. Usually, this results in soil-like sludge destined for landfills. However, Royal Thai saw this not as a problem, but as an opportunity for innovation.
Collaborating with a local fertilizer manufacturer, they discovered a practical application for biological sludge in the production of fertilizer pellets. Together, they adapted the water processing system to produce waste sludge that meets the stringent standards set by the Department of Works for agricultural use, transforming it into high-performance commercial fertilizer.
Sowing the Seeds of Sustainability
The result is a beautiful circle of life - the sludge is delivered to the fertilizer company, blended with growing nutrients like Dolomite, Marl, Nitrogen, Phosphate, and Potassium, and then converted into fertilizer pellets. These pellets support the growth of local crops such as Pineapple, Cassava, Sweetcorn, and Rubber Trees.
Since the initiative began in 2015, Royal Thai has donated nearly 2000 tons of sludge, which has been turned into more than 400,000 bags of fertilizer. This achievement is a testament to how business can coexist harmoniously with the environment, creating an ecosystem where waste is not wasted, but put into service for new life.